Trim panel



P. R. ZINSER TRIM PANEL Sept. 3, 1940.

Filed April 20. 1936 INVENTOR. Z 25er ATTORNEY.

Pefeeted sept. 3, 194e PATENT OFFICE 'ram PANEL raul n. zinsen, neuen, Mich., assigner to wooden Industries Incorporated, Detroit, Mich., a corv poration of Michigan L Application April 20, 1936, Serial No. 75,321

A I 6 Claims. This invention relates to improvements in fabricated trim panels and improvements in the n method of fabricating ysuch panels.

f An object is to provide a trim panel, part cularly designed for the interior of lan automo ile body, which presents the appearance of an expensive upholstered padded trim panel at low cost and without stitching.

Another object is to provide a padded'- trim 10 panel of superior quality which presents an upholstered tufted appearance without actually tufting or stitching` the same. The panel is charac'terized in that it may be fabricated of inexpensive materials at low cost and it is of durable l5 and moisture resistant construction.

Another object is to provide an improved method of fabricating a padded trim panel without stitching or tufting and at low cost and so as to present any desired design of tufting or the like.

This improved panel comprises a panel foundation, such as ber board, a soft layer of lwadr ding overlyingthe board and an outer covering of trim material. Theseveral layers are adhesively secured together and the tufted design is obtained by adhesive saturation of the wadding along determinedlines. of compresssion and adhesive securement of the wadding in its compressed state to the board along -such lines. Along such lines the trim material is likewise adhesively fastened down.

The wadding throughout its .uncompressed areas is fluffy, resilient and' unsaturated with adhesive though normally highly absorbent.

The uncompressed areas of the wadding are pro-- tected against moisture absorption by a surrounding moisture resistant barrier. This barrier comprises a moisture resistant sheet overlying the wadding, a moisture resistant supporting panel and moisture resistant adhesive satu- 40 rated densied lines of compression of the wadding itself connecting the overlying barrier sheet to the supporting panel. Such barrier sheet like-f wise protects the layers underneath the trim fabric from the action of cleaning solutions used on the fabric as the barrier is resistant to the attack of such cleaning compounds. This barrier further is important as certain panel foundation boards carry a binder whichl is soluble in cleaning compounds and the overlying barrier protects the foundation board against. the attack of such cleaning compoundsfwhich are widely used. 1

An important characteristic of the improved method comprises the adhesive saturation of the 5 5 wadding along lines of compression by absorption of adhesive from the adhesive coated surface of the panel board through compression of the wadding along such lines against the board.v The method is further characterized in that the uncompressed' areas of wadding do not absorb 5 adhesive but remain loose, iiu'iy and resilient. Compression of the absorbent wadding against the adhesive coated surface of the foundation along determined lines sov saturates the wadding along such lines of compression as to produce 10 permanent adhesive densication of the wadding therealong and fastens the trim cloth along such lines securely to the board producing the desired padded configuration.

An important feature is the employment of an 15 adhesive such as a latex compound which is applied to the foundation board and to the trim material and which upon 'compression of the intermediate wadding layer securely fastens the trim material to the board along such compressed 20 line.

Another important feature is the provision of a. latex saturated barrier sheet overlying the wadding and forming a backing sheet for the trim cloth which barrier sheet readily adhesively picks 25 up and retains its connection with the latex absorbed by the wadding along the line of compression.`

A further meritorious feature is that this latex saturated backing sheet may preferably comprise 30 a latex saturated tissue thin outer cover sheet of the wadding itself which forms an adhesive connection with the latex coated inner surface of the trim cloth and with the -latex saturated compressed portion of the wadding.

In the method 'a preferred step is to compress the' wadding and adhesively secure the same in the compacted state along relatively wide lines of compression. The trim cloth is then adhesively secured to the wadding along such compacted w line but compressed thereagainst along a line relatively less wide than the compacted line of wadding.

Other objects, advantages and meritorious features of this invention will Vmore fully appear 45 from the following description, appended claims and accompanying drawing, wherein: l

Figure l is an elevation of a trim panel embodying my invention,

Fig. 2 is a cross-sectional view takenon the 50 line 2-2 of Fig. 1,

Fig. 3 is an enlarged cross-sectional view-of a fragment of a panel embodying my invention,

Fig. 4 is an elevation of a fragment of the panel embodying my invention, and

Fig. 5 is an enlarged cross-sectional view of .a

i panel on the line 5--5 of Fig. 1 but illustrating the appearance after compresssion of the wadding but prior to the securement of the trim cloth.

In Fig.. 1 I have shown a panel presenting a padded design but it is to be understood that any desired type of design may go with the panel as the method here set forth is adaptable to em- A bossed designs of any shape.

In the fabrication of a panel embodying my invention there is provided a foundation board such as is indicated at I0. This may be any suitable type of composition ber board; It is desirable that such board be moisture resistantl in order to prevent warping, buckling and the like, and a board which I have found satisfactory is a board formed of cellulose fibers held together by a suitable binder such as an asphaltum composition binder. Such a board is well-known on the market under the name of K B board. It may be stamped or otherwise'shaped as it possesses thermoplastic characteristics which permits it to respond to heat and pressure to assume and permanently retain a deformed shape. It is of course understood that such a type of board is not essential as the embossed appearance is given to the design by the embossment of the wadding as hereinafter described.

A layer of wadding is providedto overlie the surfaceof .the board. It'is desirable to have a soft, fluffy, resilient,inexpensive wadding, and a wadding whichv has been found satisfactory is one formed of loosely integrated cellulose fibers. As

here shown, such wadding is indicated as I2 and paper saturated with latex so as to strengthen it and render it moisture resistant. This cover sheet forms a support and protection for the loose wadding and facilitates its handling. It likewise forms a cover therefor to preventy ingress of moisture from the trim side. 'I'he cover sheet also serves other important functions.

' The panel is trimmed with upholstery trim material. This may be a fabric sheet such as indicated at I6 or 2E, or it may be a sheet of artificial leather or any other desired flexible trim sheet.

This upholstery fabric forms the outer cover of the panel structure and in the completed panel may be folded over the edge onto the back'thereof as indicated at I8 and adhesively secured to the back of the panel to provide a-flnished panel and to protect' the edge of the wadding and 'to hold the same downl at themargin of the panel.

In the fabrication of the panel one surface ofthe panel foundation board is covered with a generous coating of a suitable adhesive such as latex compound indicated in exaggerated thickness as a layer 20 in Figs. 3 and 5. One surface of the trim material I6 -is likewise sprayed with an adhesive compound of a similar character indicated as at 22 in Fig. 3. `The wadding layer I2 with the protective sheet I4 is placed upon the i adhesive coated surface of the foundation board. The adhesive coating 20 on the foundation board secures the wadding layer I2 thereto.

The panel and Wadding is-then placed in a suitable die and subjected to a die stamping operation to impart the desired embossed design thereto.I The die is so fashioned that it compresses the wadding against the foundation board only along the lines of desired debossment. The die is recessed between these projecting portions so that Athe wadding is not compacted throughout the areas between the lines of compression. In Fig. 5 the wadding is shown compressed against the foundation board at 24. Between the lines 24 the wadding is not compressed. Along these lines of compression the wadding absorbs sufficient adhesive throughout its compressed area from the adhesive coat on the foundation board to thoroughly saturate the wadding. Along the line of compression the wadding assumes and permanently retains its compressed state due to this compacted adhesive securement of the fibers thereof together. The latex securely bonds the fibers of the wadding together and engages the latex saturated sheet I4 forming a secure connection therewith. This line of compression is relatively Wide. The wadding is densified along such line forming a sealed line around each uncompressed area.

The adhesive coating 20 on the foundation board is supplied in such thickness that upon compression of the layer of wadding thereagainst there is sucient adhesive to penetrate through the compresse thickness of wadding but there is not sumcient adhesive to soak through the wadding over its uncompressed areas. Throughout the areas which are not compressed the adhesive merely secures the wadding adhesively to the board but does not substantially penetrate or soak therethrough.

The trim fabric 26, coated on its under side with similar latex adhesive is now placed over the wadding. The complete panel'is then placed in a die of the same general contour as used to compress the Wadding but constructed to produce lines of compression of substantially less width as illustrated in Fig. 2 and provided with cooperating force and die members adapted to give a lnel shape to the wadding and to impart the embossed design to the foundation board as shown in Fig. 2. The slope of the trim fabric is relatively gentle from the depth of the compressed line outwardly toward both sides. There is not the sharp rise that would be the case if the wide line were not first established in the w'adding. The wide line of compression in the wedding also provides ya secure connection with the board.

` If a particularly heavy and thick wadded area is desired, a piece of wadding 21 may be cut to size and placed upon the layer of wadding I2 and the line 24 of compression conforms so as to encircle this cut piece of wadding. This might be necessary if the layer of wedding I 2 plus the layer 21 would be to thick to absorb throughout its entire thickness the required quantity of adhesive to form the bond.v along the line of compression.

In Fig. 4 I have shown a depressed line wherein the die force is so formed as to provide imitation stitching-indicated by depressions 28 formed in thebottom of the groove 24 as is set forth in my Patent No. 2,019,641; The particular invention herein'described lends itself to such type of die stamping in' that it readily responds to the formation of these artificial stitch depressions.

The wedding4 which I provide is relatively' highly absorbent and the adhesive quickly soaks through the compactecllines Aor portions thereof Due to the fact that the cover sheet I4 is latex saturated it quickly picks up the latex soaking through the compressed line of wadding and forms a secure connection therewith and holds the wadding to the desired embossed design and likewise holds the trim fabric to the foundation board. The uncompressed areas of wadding are practically hermetically sealed. n e

The barrier sheet I4 not only protects the wadding against moisture but preyents cleaning materials which may be used to clean the upholstery fabric from soaking into the wadding and also from acting upon the foundation board I0. Certain widely used cleaning materials are of such a,`

characterV as will dissolve the binder in the foundation board. 'I 'he binder then flows to .the surface and discolors the trim fabric. 'Ihe cover sheet I4 being resistant to the attack of these cleaning fluids prevents them from reaching the foundation board and likewise prevents the binder inthe board from soaking through the wadding to contaminate theupholstery cloth.

What I claim is:

1. A trim panel comprising a foundation board,

a layerfof wadding overlying the board,\a layer of trim material overlying4 the. wadding. said wadding being saturated with adhesive and compressed against the foundation board along a relatively wide line surrounding an uncompressed area throughout which the wadding is adhesively secured to the board but is not compacted theref against, said trim material being compressed along a relatively narrow line against the rela,- tively wide compressed line of wadding and secured adhesively thereto.

2.I That method of fabricatingla-trim panel comprising placing a layer of wadding over a. foundation board,- compacting and adhesively se- 'curlngthe same compacted thereagainst along a predetermined line of'substantial width, placing ding through said compressed line of adhesive saturated wadding said wadding throughout its uncompressed area being unsaturated with -said adhesive.

4. A trim panel vcomprising a foundation layer having one surface provided with an adhesive coating, a layer of adhesive absorbent wadding overlying the surface of the foundation layer provided with the adhesive coating, a layer of trim material overlying the wadding, said wadding being compressed against the foundation layer along a line-dening an uncompressed area of wadding and saturated along said line with adhesive absorbed from the foundation layer and adhesively secured compressed together and to the foundation layer along said line by said absorbed adhesive, said trim material being adhesively secured to the foundation layer along said line of compression of the wadding through said compressed line of adhesive saturated wad' ding, and a second layer of wadding underneath the trim layer overlying the first layer of wadding throughout the Auncompressed area thereof only, and spaced withinv thesaturated compressed line of the first layer of wadding and positioned upon said rst layer of wadding by the adhesion of the trim material to the first layer along said saturated line of compression both layers of wadding throughout the uncompressed area being unsaturated with said adhesive.

5. That method of fabricating a laminated trim panel structure comprising providing a foundation layer-'with a coating of adhesive, placing a layer of absorbent wadding upon said coated surface of the foundation layer but without sorbent of said adhesive and said adhesive being l Ipresent in sufficient amount that upon compression of the wadding into a densled line against a sheet of trim material over said wadding and compacting the same against the compacted line of wadding along a line of relatively less width thanfsaid compacted line-ofwaddlng adhesively securing the trim sheet thereto.

' 3. 1A trim panel comprising a foundation layer having one surface provided with an adhesive coating, a layerlof adhesive absorbent wadding overlying the surface of the foundation layerA provided with the adhesive coating, a layer of trim material overlying the wadding, saidwadrial being adhesively secured to the foundation layer along said lineof compression ofthe wadthe foundation layer the wadding along said line absorbs adhesive from the foundation layer saturating the wadding throughout along said line, compressing said wadding along a line defining lan uncompressed area of wadding against the adhesive coated surface of the foundation layer, densifying the wadding along said line and causing it toI absorb adhesive throughout along said line adheslvely securing the wadding compacted tnogether and to-the foundation layer along said 6. A. 'laminated trim panel comprising a foundation layer provided upon one surface with a coating of adhesive. a layer of absorbent uncompressed wadding oi substantially greater thickness than the foundation layer overlying the adhesive coatedsurface of the foundation layer and secured thereto by said adhesive coating but without saturation throughout the uncompressed area therebyfa moisture resistant cover sheet overlying the wadding. a layer of trim material overlying the cover sheet, said wadding being compacted against the foundation layer along a line outlining an uncompressed area and com- .pacted sufficiently so that the adhesive-coating on the foundation layer saturates the wadding throughout along the line of compression securing the wadding adnesively compressed together' along said line and against said foundation layer.

' PAUL al znzsmt. e 

